Application of fuzzy failure mode and effect analysis to investigate lean wastes in the sewing section
International Journal of Quality & Reliability Management
ISSN: 0265-671X
Article publication date: 27 March 2024
Abstract
Purpose
This study aims to quantify and prioritize the main causes of lean wastes and to apply reduction methods by employing better waste cause identification methodologies.
Design/methodology/approach
We employed fuzzy techniques for order preference by similarity to the ideal solution (FTOPSIS), fuzzy analytical hierarchy process (FAHP), and failure mode effect analysis (FMEA) to determine the causes of defects. To determine the current defect cause identification procedures, time studies, checklists, and process flow charts were employed. The study focuses on the sewing department of a clothing industry in Addis Ababa, Ethiopia.
Findings
These techniques outperform conventional techniques and offer a better solution for challenging decision-making situations. Each lean waste’s FMEA criteria, such as severity, occurrence, and detectability, were examined. A pairwise comparison revealed that defect has a larger effect than other lean wastes. Defects were mostly caused by inadequate operator training. To minimize lean waste, prioritizing their causes is crucial.
Research limitations/implications
The research focuses on a case company and the result could not be generalized for the whole industry.
Practical implications
The study used quantitative approaches to quantify and prioritize the causes of lean waste in the garment industry and provides insight for industrialists to focus on the waste causes to improve their quality performance.
Originality/value
The methodology of integrating FMEA with FAHP and FTOPSIS was the new contribution to have a better solution to decision variables by considering the severity, occurrence, and detectability of the causes of wastes. The data collection approach was based on experts’ focus group discussion to rate the main causes of defects which could provide optimal values of defect cause prioritization.
Keywords
Acknowledgements
We would like to acknowledge respondents in the industry and domain experts who willingly participated in the survey and group discussion to provide us with professional data or information in their discipline and workplace. We are also very grateful for the financial support of Ethiopian Institute of Textile and Fashion Technology, Bahir Dar University.
Citation
Agazhie, T. and Hailemariam, S.S. (2024), "Application of fuzzy failure mode and effect analysis to investigate lean wastes in the sewing section", International Journal of Quality & Reliability Management, Vol. ahead-of-print No. ahead-of-print. https://doi.org/10.1108/IJQRM-12-2023-0407
Publisher
:Emerald Publishing Limited
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